佐藤電機製作所 Product Lineup

We propose a chrome plating-free process that eliminates the chromate plating treatment and introduces a case where the production lead time for parts was shortened by one week. In response to frequent requests for short lead times for semiconductor equipment parts, the conventional chromate plating process extended the lead time. While cost reduction was also a challenge, customers particularly highlighted the shortening of lead times as the most critical issue. By changing from conventional steel materials to black ZAM materials with high corrosion-resistant plating, we were able to shorten lead times and achieve cost reductions of up to 10-20%. Furthermore, the dense plating layer unique to ZAM materials exhibits far superior corrosion resistance compared to conventional hot-dip galvanized steel sheets. [Challenges] ■ The conventional chromate plating process extended lead times in response to frequent requests for short lead times for semiconductor equipment parts. ■ Cost reduction and, in particular, lead time shortening are necessary. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where we proposed the painted steel sheet "View Coat" to shorten the painting process after sheet metal processing. The customer required a solution for an outdoor cabinet for gasoline station payment machines that simultaneously addressed cost reduction, lead time shortening, and conductivity for internal equipment's electromagnetic interference. Meeting these multiple requirements was a challenge. Therefore, we selected a type with high corrosion resistance and heat absorption that meets conductivity standards. This eliminated the need for a painting process, achieving a cost reduction of up to 30% and shortening the lead time. 【Case Overview】 ■ Challenges - For an outdoor cabinet for gasoline station payment machines, cost reduction, lead time shortening, and conductivity for internal equipment's electromagnetic interference were required. ■ Proposal/Results - We proposed the painted steel sheet "View Coat" to shorten the painting process after sheet metal processing. - This eliminated the need for a painting process, achieving a cost reduction of up to 30% and shortening the lead time. *For more details, please download the PDF or feel free to contact us.

We received a request to reduce the cost of rack attachments, and we would like to introduce a case where we proposed a paint-free solution to a customer, as manual powder coating on SPCC and SECC accounted for a large portion of their costs. The challenge was that the long and narrow parts were difficult to automate, leading to rising labor costs due to manual work. To address this, we changed the materials from SPCC and SECC to paint-free materials such as 430KD and 304KD, thereby reducing both the painting process and labor costs. This resulted in significant cost reductions and shortened lead times. [Challenges] - There was a request to reduce the cost of rack attachments, with manual powder coating (melamine) on SPCC and SECC accounting for a large portion of the costs. - The long and narrow parts were difficult to automate, leading to rising labor costs due to manual work. *For more details, please download the PDF or feel free to contact us.*

We would like to introduce a case where the use of resin molds for prototype production significantly reduced costs and time during the early stages of development. In the case of single-item production and small-lot processing, there are many instances where mold production is necessary, resulting in a combination of mold costs and processing fees that lead to very high costs. In particular, the costs and time associated with molds during the prototype stage have been a significant burden, and improvements have been sought. Therefore, we propose the use of resin molds for prototype production. This approach allows us to reduce mold costs to less than half compared to metal molds. At the same time, we achieved shorter delivery times, enabling flexible responses for prototypes. While there are approaches such as layered molds for prototype molds, we recommend resin molds that can achieve shapes as close as possible to the original mold. [Challenges] ■ The combination of mold costs and processing fees results in very high costs. ■ In particular, the costs and time associated with molds during the prototype stage have been a significant burden, and improvements have been sought. *For more details, please download the PDF or feel free to contact us.

We would like to introduce a case where the use of laminated jigs improved prototype costs and lead times. Previously, we outsourced welding jigs used during welding to other companies, which was a factor in high costs. While jigs are essential for accurate and reliable welding, the outsourcing costs remained a continuous issue. By changing the process to manufacture laminated welding jigs in-house, we achieved stabilization of quality and reduction of lead times without incurring additional costs. We succeeded in improving efficiency and reducing costs through in-house production, thereby enhancing productivity. Our company is working on speeding up processing and reducing costs with laminated welding jigs, eliminating the high costs and long lead times associated with outsourcing traditional jig manufacturing, and enabling immediate response through in-house production. [Challenges] ■ Outsourcing welding jigs used during welding to other companies resulted in high costs. ■ While jigs are essential for accurate and reliable welding, outsourcing costs remained a continuous issue. *For more details, please download the PDF or feel free to contact us.